Battery terminal post broke off

aah924

While driving my car, earlier in the week, it suddenly lost all power and died. When I lifted up the seat, I found that a battery terminal post had completely broken off. This is a 48 volt cart with a Plum quick motor upgrade. Any suggestions on how to prevent this is the future or is this just bad luck? I did check to make sure that all of the connections are tight.

Thanks!

Attached Images

GolfCartBattery.jpg (102.0 KB, 0 views)

BGW

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mrgolf

Never seen that before. They may have been so tight it pulled loose. You don't have to crank down on the nut, just snug. I'm not saying you over did it, just that it can happen. Looks like that could be melted back on, but I don't think I would try it with a live battery. The drill and tap repair would be best. I would remove battery from cart even before doing that. Too big a chance to blow something up with all the other batteries in there.

DIRTPIT HC

Default Re: Drill and tap melted battery terminal?
I use an 11/64" Drill bit and drill one inch deep. Tap it with a 5/16 tap and put a bolt in it. 5/16" x 1"
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David Hicks
Owner/Operator - Revolution Golf Cars

This is a quote from a post where tahoedog71 explained how to fix.

DIRTPIT HC

Above quote was from TahoedawgZ71. Do a search and a bunch of stuff comes up.

Sergio

That was a typo, David corrected the size on the next post to 17/64".

http://www.buggiesgonewild.com/elect...ml#post1062725

Birddog4x4

Yep, that was my thoughts exactly.... good looking out and great info

I think my tap and die set is my best tool I have, saves alot of money thats for sure!

scottyb

Another option is to contact a battery store about re-pouring the post.

teecro

If a recast is not an option...

Myself I would not use a 17/64" (.2656") bit for an 5/16"-18 bolt as this is going to result in slightly shallow threads which can make pull out easy in soft lead.... The proper bit is an F bit at .2570" to which in soft lead a 1/4" bit will give very nice results with no fear of tap breakage....

Dave Box

Just asking out of curiosity, because I am not a sparky, but why could you not cut off the end of the cable, fit one of these and use the undamaged post.

Dave

Attached Images

term.jpg (8.9 KB, 0 views)

teecro

Hard to tell from the OP post if that is a full height DT terminal or just a nub from a ELPT terminal....